Flexible underlie for rugs



Dec. 16, 1952 F. W B|NGELL 2,622,039

FLEXIBLE UNDERLIE FOR RUGS Filed March 15, 1950 INVEN TOR.

Patented Dec. 16, 1952 UNITED STATES PATENT oFF-lcs 2,622,039 FLEXIBLE UNDERLIE-'Fo'n Roos Fera W. Bingen, Cleveland, ohio Application March 15, 195o, v.isteria-ivo. 149,790

4i Claims.

Y Ihisinvention relates uto an underlie for rugs and other floor coverings "and particularly to a non-skid underlie which is flexible atwi'se so as to conform to the general plane'and contour o f thefloor and is operative to grip highly polished floors or other supporting surfaces frictionally so as to retain its Vposition thereon and to engage the underside of a rug so as to retain the rug in vfixed position in the plane of, and relative to, the underlie. y Y s The invention also relates toa method of mal:- ing an underlie such as above described.

Theunderlie comprises essentially coarse open mesh metal fabric composed 'of strands of flexible o wire which are of realt'ively small diameter, or of narrow strips' of metal which are relatively thin, so that it is flexible atwise, the strands of the fabric being coated with soft resilient rubber or rubber composition, with the composition spanning and closing the mesh and protruding from the fabric at the underside in the form of multitudinous small soft resilient protuberances Which arealigned withvthe'meshes, respectively, and of which baseportionsin the plane of the fabric are constrained by the strands from expansion laterally in said plane, the protuberances being spaced apart from each other so as to engage a flooror supporting surface and frictionally constrain the underlie from movement therealong,

and the 4underlie having means exposed on its upper surface whichare operative to engage the undersurface .of the rug and constrain it from movement relative to the underlie.V s

l The method of making'the'underlie comprises essentiallyV applying on the open. mesh metal fabrica fc'oatin'gof rubber or rubber composition inoplastifo condition which sets in Asoft and resilient Condition and while the rubber or composition is in plastic condition applying pressure to the'composition from one face of the fabric to cause the composition to embed the fabric and to cause the part of it'which bridges the openings in the fabric to bulge and protrude outwardly from'the face of the fabric in the form of lmultitudinous protuberances respective to and aligned with the openings and forming va roughened surface on the opposite face of the fabric by the configuration of the rubber or composition or the bonding thereto of irregular particles or granules of material.

n Heretofore, underlies have been provided in th'e form of a sheetof rubber or rubber composition having a plurality of bulges distributed over the undersurfac'e and with a network of integral ribs interconnecting the adjacent :bulges. the op- 2 posit@ fade of the. ufridrlie. hragna correspondingto the bulges or protuberances and to the ribs, respectively. Such mats whilevreducing slippage. Qf the $191901 ted T hav@ a tendhy to creep Valong the supporting floor andto` creep relative to the rug, apparently Jdue tothe yelastic deformation and expansion and recovery o fY the underlie along its plane, .this deformation `being distributed and transmittedover a, substantial area of the vunrglerlie.surroundingv the pointl of application of pressure. For example, pressure applied normal to the underlercauses vertical compression of the bulges orwpads .with consequent lateral expansion thereof, The resiliency of the composition does notcompletely absorb the resultantlateral components of movement. Since the bulges or protuberances adjacent to those under vertical compressionare resting on the floor only under the limited weight of the rug and their own weight and are notY gripping the floor rmly, theyfare moved slightly outwardly from. the areavof applied pressure.V Y Upon removal of the pressure those protuberances originally compressed `no longerfirmly grip the floor so that when they contract toward v,original condition, they can do so as readily by moving them.- selves slightly toward thel padjacent bulges or protuberances as by drawing the adjacent protuberances :back towardvthemselves. Thuswith each application of pressure there isa small in,- crement of movement or shift of the underlie along the floor surface. This is increased to some extent by the manner of application of pressure applied by the foot of one walking on the floor. Such pressure, due to rockingof the foot of the wearer rfrom thekheel to the b all of the foot or about the ball of the foot causes the pointofv ap. plication of pressure to travel along the lplane of the underlie much as though a. roller were rolled across the rug. Thus a bulge adjacent the instantaneous point of pressure application is moved slightly by lateral expansion `of the bulges or protuberances under pressure and while so moved is .itselfl placed under pressure in its changed position and thus grips the` floor tightly as the pressure on theoriginal protuberance is released. Consequently4 the released bulge inrestoring itself draws itself toward the -now compressed vadjacent bulge which is rmly held against the oor by the pressure. These minute increments of movement cause Agradual creepage of the underlie. A,

In accordance with the present invention, each of the protuberances of the underlie is individually confined at its base portion in the plane of the underlie by non-elastic strands of metal so that any lateral expansion of the base portion of a given protuberance under downwardly directed pressure is prevented, the resultant forces normally tending to cause such expansion being balanced by reactant forces of the wire strands instead of being distributed and transmitted to adjacent areas of the underlie. Consequently there is no initial displacement or movement in the plane of the underlie of the bulges adjacent the pressure area and consequently no permanent increment or displacement of travel of the underlie. Instead, each protuberance acts as a selfcontained and independent unit so far as elastic deformation is concerned, yet the base portions of the multitudinous units are secured in fixed position relative to each other in the plane of the underlie. Furthermore, the protuberances preferably are of large projected area in the plane of the underlierelative to their greatest dimension normal to such plane, thus making them operable to flatten and engage a large area of the floor with a minimum of resultant expansive force in the plane of their bases. The wire fabric bonded with rubber composition develops a very high degree of rigidity in its plane. Likewise the proportions of the protuberances greatly reduce any tendency of them to roll about their points of contact with the floor under a force having a component normal to the floor and one parallel to the floor. If the protuberances are of a height which is large relative t0 their projected area in the plane of the underlie, these would have a much smaller area bearing against the floor in relation to their height and would tend to rock about the contact area, due not only to the parallel component of the force but overbalance of the normal vertical component. Thus their bases in the plane of the underlie would tend to travel appreciably parallel to the floor.

Preferably, therefore, the protuberances of the present underlie are of large projected area relative to their height. For example, if the projected area is round it may have a diameter of about three to five times the overall thickness of the underlie. Y The overall thickness of the underlie should be kept as small as possible having due regard to strength and to the amount of padding desired beneath the particular rug. An underlie having an overall thickness of about M3 inch to 1%; inch and preferably about 1A; inch is preferred for most conditions.

The objects and other advantages of the present invention will become apparent from the following description wherein reference is made to the drawings, in which:

Fig. 1 is a top plan View of a fragment of an underlie embodying the principles of the present invention, portions thereof being cut away for clearn'ess in illustration;

Fig. 2 is a cross sectional view taken on the line 2 2 of Fig. l;

Fig. 3 is a bottom plan view of the underlie illustrated in Figs. l and 2;

Fig. 4 is an end elevation of the underlie in operating position between the rug and floor, the floor being shown in section;

Fig. 5 is a top plan view similar to Fig. 1 illustrating a modification of the underlie of Fig. l;

Fig. 6 is a cross sectional view taken on the line 6-6 of Fig. 5;

Fig. '7 is a top plan view similar to Fig. 1 illustrating another modification of the underlie, part thereof being cut away for clearness in illustraion;

Fig. 8 is a cross sectional view taken on the line 8 8 in Fig. 7;

Fig. 9 is a fragmentary enlarged sectional View taken on the right hand offset portion of the line 8-3 in Fig. 7 and corresponding to the right hand portion of the underlie shown in Fig. 8;

Fig. 10 is a top plan view of a fragment of an underlie similar to Fig. 1 but with a metal fabric of flat strands instead of round wire strands, illustrated in Fig. 1; and

Fig. 11 is a right end View of the metal fabric cf the underlie illustrated in Fig. 10.

Referring to the Figs. 1 through 3 inclusive, the underlie there illustrated comprises a coarse open mesh fabric l of metal, such as woven wire or offset metal which is relatively stiff in its plane but readily flexible flatwise. The metal fabric l is embedded in and bonded to a matrix, indicated generally at 2, which preferably is of soft resilient rubber, either real or synthetic, or to a composition of one or both. The term rubber" as used throughout the description and claims is meant to include any one or a mixture of the above materials of the matrix inasmuch as the physical characteristics rather than the chemical characteristics are controlling. The matrix 2 is shown as being comprised of two layers, 3 and A, respectively, integrally bonded together and to the metal fabric so as to provide a unitary structure, the particular construction shown resulting from the method used in manufacture thereof.

The metal fabric, as stated, is preferably open and preferably of relatively coarse mesh yet is sufficiently flexible so that the resulting underlie can conform readily to the variations in supporting surface or floor. The strands of the metal fabric are relatively thinly coated with the matrix and the matrix spans and closes the openings of the fabric. At the underside the matrix is in the form of multitudinous well-defined protuberances which are aligned with the openings of the fabric respectively, and are spaced apart from each other laterally. Each protuberance is gen erally in the form of a spherical sector on its undersurface, thus presenting a rounded or globular convex surface downwardly. The base portion of each protuberance, which portion is that lying between the planes of the metal fabric, is confined and restrained from lateral expansion in the plane of the fabric. Thus to a great degree the individual protuberances are isolated from each other so far as lateral elastic deforma.- tion is concerned. As a result lateral expansion of one protuberance does not transmit any bodily movement to those adjacent thereto. The protuberances 5 are large in horizontal projection relative to their height 0r dimension normal to the plane of the underlie. The upper surface of the underlie formed by the top layer 4 is also of soft resilient rubber and as mentioned is integrally bonded to the upper surface of the lower layer to form the matrix.

On the exposed upper surface of the top layer 4 are roughening means for engagement with the rug to anchor the rug against relative movement in the piane of the underlie.

In the form illustrated in Figs. 1 through 3 the anchor means comprises relatively coarse irregular particles or granules 6 of material, such as ground cork, ground or shredded rubber or rubber and ber composition, and the like. These particles may be resilient to some degree so as not to cut or damage the rug but usually are much less resilient than the matrix. These are bonded or cemented to the matrix, depending l5 upon themanner of manufacture, and are evenly 'distributed over fthe upper surfacea'nd present a multitude-of -peaks or projectionswith valleys therebetweenso -as-to vbetter engage and'hold the rug.

'The underlie illustrated in Figs. 1 through `3 isi-shown in Fig.-4 in operating-position on a floor F supporting -a rug R.

' `If desired, the upper layer d may be omitted vand lthe particles -applied directly on the vupper surface of the layer.

-Such a modification is shown inFigs. 51and'6 in which the irregularities normally occurringin the upper surface, due to the cross strands rand open-mesh of the fabric, assist inrestraining the rug Vfrom sliding and creeping on the underlie.

Referring specifically to Figs. 5 `and-6, the open mesh metal fabric is indicated at l and is coated by matrix -8, the coating of the individual strands being relatively thin and the fabric lying lnear the upper surface of the matrix. The lower face of the matrix is in the form of a multi'tude'of protuberances 9 similar in form and operation to the protuberances 5. Irregular coarse particles Ill of materials are 'distributed over the upper surface of vthe matrix and bonded thereto. The main difference in the two forms described is in their thickness and result largely from their respective methods of manufacture. In the form illustrated in Figs. 1 through 4 the fabric l is spread hori- Zontally and a layer of the rubber in viscous condition, as a result of plasticizing by heat or by a Volatile solvent or plasticizer, is spread-approximately Auniformly over the upper surface. Next a lsheet of rubber is laid over the Viscous rubber layer and pressed evenly `downwardly thereagainst, thus forcing the viscous rubber through the mesh of the fabric and around the individual strands, thoroughly coating the latter. The pressure is continued until the desired portion of the viscous rubber has passed through the mesh and formed protuberances of the desired height at the underface, these protuberances automatically taking the spherical shape heretofore described. This also bonds the upper layer or sheet 4 to the layer 3 of viscous rubber and the underlie becomes a unitary structure with the fabric Well embedded therein and bonded thereto. The top of the layer 4 is then sprinkled with the particles or granules of material and these are lightly pressed thereagainst so as to make them adhere or to partly embed them while leaving a number of irregularities exposed above the normal plane of the layer 4. The sheet or layer 4 might be of somewhat plasticized rubber in which case the particles can be bonded thereto before setting. If, however, the sheet or layer 3 is already set, a coat of cement may rst be applied for bonding the particles thereto. Likewise, if desired, the wire fabric, before placing the layer 3 of viscous rubber thereon, may be lightly coated by brushing it with a small quantity of the same or like material, thus assuring that all strands of the metal fabric will be coated and bonded to the final underlie.

The pressure may be applied to the upper surface by means of a roller or platen, the roller or platen preferably being steam heated and of the usual type having a porous surface through which steam and moisture can escape against the surface of the material to prevent sticking of the rubber to the platen or roller. The latter type of platen or roller is particularly desirable in producing the underlie of Figs. 5 and 6 due to the ror in other shapes.

tackiness 'of .the viscous :rubb'er'which is directly 'exposed tothe platen or roller. l

Air Lpressure also may be applied to the upper face for yforming the-protuberancesbut 'in Jsuch case care .'must'be exercised lto assure `that the viscous rubber is of uniform consistency and will flow evenly. Y

Referring next to Figs. 7 through 9, :another modification of the underlie is illustrated. In this form opencoarse mesh metal fabric -I-i of woven wire is `thinly coated with rubber matrix l2 which spans `across and closes'the mesh. Atthe-underside of the lunderlie the ymatrix is in the Afo'rm'of thin walled protuberances `l3 which present downwardly exposed convex surfaces inthe-shape of spherical segments such as heretofore described. However, the upper vsurfaces of the protuberances arefconcave. 'I'hus the uppersurface of the underlie has a multitude `of regularly distributed depressions between the strands as well as slight peaks at the intersections ofthe strands. This irregularity in surface contour provides an effective surface for engagement with the rug to constrain it from movement relative to the underlie. As in the other forms, the bases of the protuberances I3 in the plane of the fabric are confined against lateral expansion and movement and since the depending portions of the protuberances are thin walled and flatten readily under pressure, a large area of each is exposed to and engages the floor without transmitting increments of movement to adjacent protuberances. This form of underlie can bel made very readily by coating the metal fabric with very stretchy and resilient rubber composition which is more ilowable than that heretofore descrilcv'e'd.v Preferably the rubber or composition is rendered fiowable by means of a volatile solvent. After coating the fabric with a layer of the desired thickness the coated fabric is supported in horizontal position and a moderate air stream is blown against the upper surface, the force of the air stream depending somewhat upon the fluidity or flowability of the matrix. The force of the air stream is maintained against the coated fabric until the protuberances I3 are formed and may be maintained, though usually with lessened force, until the material has set by evaporation of the solvent. Since the upper surface of this form of the underlie contains many crests and depressions, the crests and depressions provide an anchor means for the rug and the addition of the lcoarse irregular particles on the upper surface is unnecessary.

It is to be noted that in all of the gures the thickness of the material has had to be exaggerated for clearness in showing sections and the like and that, therefore, the drawings without explanation may give a distorted picture of the proportions of the underlie.

In Fig. 9, however, the proportions are suitable, assuming the mesh is about one-half inch.

Considerable variation may be made in the underlie but the protuberances should be large in horizontal projection relative to their height in any case. The mesh may be square, rectangular As a suitable example, an underlie employing a fabric with a square mesh of from one-half to one and one-half inches may have protuberances of about one-eighth to threeeights inches high. In the form illustrated in Figs. 7 through 9 the overall thickness of the underlie using a mesh having woven wire strands of about one-thirty second inch diameter and mesh one-half inch square is about one-quarter inch.

Referring next to Figs. 10 and 11, an underlie indicated generally at I 4 using a coarse open mesh fabric of flat metal strands is illustrated. This underlie is the same as that heretofore described except for the type of strand shown and is particularly desirable Where very limited height of the underlie is desired.

'Ihe form of underlie to be used in a given case is dictated largely by the desires of the user. For example, for relatively light weight or thin rugs considerable padding is usually desired between the rug and oor in which case the thick underlie of Figs. 1 through 4 may be used. For rugs of moderate weight the form illustrated in Figs. 5 and 6 usually is preferred to the thicker form of Figs. 1 through 4. For thick rugs when a minimum of padding is desired, the form illustrated in Figs. 7 through 9 or Figs. 10 and 11 may be used. If desired, the underlie may be secured to the rug at the margins in any suitable manner but such is not necessary.

Having thus described my invention, I claim:

1. A rug underlie comprising coarse mesh metal fabric which is relatively rigid in its plane and flexible flatwise, a coating of resilient soft rubber composition embedding the fabric and having, extending from one face of the fabric beyond the plane thereof, a multitude of integral convex protuberances, the protuberances being aligned with and spanning the meshes, respectively, and each protuberances having its base surrounded by, and constrained from elastic deformation in the plane of the fabric by, the portions of the strands of the fabric dening the mesh with which the protuberanoe is aligned.

2. A rug underlie in accordance with claim 1 characterized in that said protuberances and underlie as a whole are non-porous.

3. A rug underlie according to claim 1 characterized in that the over-all height of each protuberance normal to the plane of the fabric is greater than the thickness of the fabric.

4. An underlie for the purposes described, comprising coarse mesh metal fabric which is relatively rigid in its plane and flexible flatwise, coated with a relatively thin layer of soft resilient rubber composition which is permanently bonded thereto and spans across the meshes, the portions of the coating spanning across the meshes being, respectively, relatively thin-walled soft resilient protuberances, each of which is convex at one face of the underlie and extends outwardly beyond the plane of the fabric and is concave toward the opposite face of the underlie, the base portion of each of the protuberances lying substantially within the plane of the fabric and the protuberances lying substantially Within the plane of the fabric and the protuberances being integrally bonded together and. to the fabric at their bases.

FERD W. BINGELL.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 297,257 Harral Apr. 22, 1884 1,080,990 Meyercord Dec. 9, 1913 1,229,284 Kempel June 12, 1917 1,364,818 Smith Jan. 4, 1921 2,104,941 Boynton et al Jan. 11, 1938 2,173,186 Swartz et al Sept. 19, 1939 2,339,142 Bodle et al Jan. 11, 1944 2,425,236 Ferrante Aug. 5, 1947 

1. A RUG UNDERLIE COMPRISING COARSE MESH METAL FABRIC WHICH IS RELATIVELY RIGID IN ITS PLANE AND FLEXIBLE FLATWISE, A COATING OF RESILIENT SOFT RUBBER COMPOSITION EMBEDDING THE FABRIC AND HAVING, EXTENDING FROM ONE FACE OF THE FABRIC BEYOND THE PLANE THEREOF, A MULTITUDE OF INTEGRAL CONVEX PROTUBERANCES, THE PROTUBERANCES BEING 